A multi-spot welding station was not meeting the target JPH.
Case Drilldown:
Station’s cycle histogram showed distinct clusters. The anomalous clusters correspond to reworks which have a high frequency, contributing to a higher cycle time.
70% of cycles do not have any rework activities. The remaining 30% contribute to time loss
Both spots fully welded
One spot OK and second spot bypassed/rework to operator
Both spots bypassed/rework to operator
Result
This RCA done for high cycle time gave actionable inputs to update the product design and make it amenable for automation.